Grip and method of making a grip

ABSTRACT

The disclosure herein includes a grip and a method of making a grip configured to be grasped by a user. The grip can include a tube with a raised portion that is configured to form a portion of the surface to be grasped by the user. The grip can further include a gripping member that can be coupled to the tube leaving a portion of the raised portion exposed such that the surface to be grasped by the user includes both the raised portion and the gripping member.

RELATED U.S. APPLICATION DATA

This application is a continuation of U.S. patent application Ser. No. 15/261,758, filed Sep. 9, 2016, pending, which is a continuation of U.S. patent application Ser. No. 14/726,093, filed May 29, 2015, now U.S. Pat. No. 9,440,128, which is a continuation-in-part of U.S. patent application Ser. No. 13/750,853, filed Jan. 25, 2013, now U.S. Pat. No. 9,114,295, which is a continuation of U.S. patent application Ser. No. 12/767,736, filed Apr. 26, 2010, now U.S. Pat. No. 8,360,898, which is a continuation-in-part of U.S. patent application Ser. No. 11/838,670, filed Aug. 14, 2007, now U.S. Pat. No. 7,862,446.

U.S. patent application Ser. No. 12/767,736, filed Apr. 26, 2010, now U.S. Pat. No. 8,360,898, is also a continuation-in-part of U.S. patent application Ser. No. 12/425,187, filed Apr. 16, 2009, abandoned, which is a continuation of U.S. patent application Ser. No. 11/412,196, filed Apr. 25, 2006, abandoned, which is a continuation of U.S. patent application Ser. No. 10/167,216, filed Jun. 11, 2002, now U.S. Pat. No. 7,137,904.

U.S. patent application Ser. No. 14/726,093, filed May 29, 2015, pending, is also a continuation-in-part of U.S. patent application Ser. No. 14/497,797, filed Sep. 26, 2014, which is a continuation of U.S. patent application Ser. No. 13/403,764, filed Feb. 23, 2012, now U.S. Pat. No. 8,845,448, which is a continuation of U.S. patent application Ser. No. 12/960,261, filed Dec. 3, 2010, now U.S. Pat. No. 8,123,627, which is a continuation of U.S. patent application Ser. No. 12/426,896, filed Apr. 20, 2009, abandoned, which is a continuation of U.S. patent application Ser. No. 11/131,832, filed May 18, 2005, now U.S. Pat. No. 7,527,564, which is a continuation of U.S. patent application Ser. No. 10/875,035, filed Jun. 23, 2004, now U.S. Pat. No. 7,585,230, which is a continuation-in-part of U.S. patent application Ser. No. 10/392,480, filed Mar. 18, 2003, now U.S. Pat. No. 6,857,971, and a continuation-in-part of U.S. patent application Ser. No. 10/746,764, filed Dec. 23, 2003, now U.S. Pat. No. 6,843,732. U.S. patent application Ser. No. 11/131,832, filed May 18, 2005, now U.S. Pat. No. 7,527,564, is also a continuation-in-part of U.S. patent application No. 11/062,046, filed Feb. 18, 2005, now U.S. Pat. No. 7,470,199, which is a continuation of U.S. patent application Ser. No. 10/392,480, filed Mar. 18, 2003, now U.S. Pat. No. 6,857,971. U.S. patent application Ser. No. 11/131,832, filed May 18, 2005, now U.S. Pat. No. 7,527,564, is also a continuation-in-part of U.S. patent application Ser. No. 11/029,328, filed Jan. 5, 2005, abandoned, which is a continuation of U.S. patent application Ser. No. 10/746,764, filed Dec. 23, 2003, now U.S. Pat. No. 6,843,732. U.S. patent application Ser. No. 11/131,832, filed May 18, 2005, now U.S. Pat. No. 7,527,564, also claims the benefit of U.S. Provisional Application No. 60/572,604, filed May 19, 2004.

INCORPORATION BY REFERENCE

This application hereby incorporates by reference, in their entireties, U.S. Pat. Nos. 6,244,975, 6,627,027, 6,695,713, 6,843,732, 6,857,971, 7,186,189, 7,347,792, 7,448,957, 7,448,958, 7,566,375, 7,862,445, 7,137,904, 7,862,446, 8,123,627, 7,527,564, 7,470,199, and 6,815,028, U.S. Publication Nos. 2006/0264268, 2009/0258722, 2009/0258721, 2005/0148401, and 2016/0107051; and U.S. Provisional Application No. 60/572,604.

BACKGROUND OF THE INVENTION Field of the Invention

This application relates to an improved grip, in particular an improved grip for use with golf clubs. Embodiments of the present invention also relate to an improved grip for golf clubs.

Description of the Related Art

Applicant has previously developed resilient grips which successfully reduce impact shock to the muscle and arm joints of a user and also provide a feeling of tackiness between a user's hands and the grip, improving upon prior art rubber grips. See, for example, U.S. Pat. No. 5,797,813 granted to Applicant on Aug. 25, 1998, U.S. Pat. No. 6,843,732 granted to Applicant on Jan. 18, 2005, and U.S. Pat. No. 6,857,971 granted to Applicant on Feb. 22, 2005.

Some of these earlier grips utilize a polyurethane-felt strip which is spirally wrapped around an underlisting sleeve that is slipped onto and adhered to a golf club shaft. The sides of the strips are formed with overlapping heat depressed recessed reinforcement edges. While such grips have proven satisfactory in reducing impact shock, the fabrication is labor intensive, particularly since the strip must be wrapped manually about the underlisting sleeve within specific pressure parameters. Additionally, it is difficult to accurately align the adjoining side edges of the strip as such strip is being spiraling wrapped about the underlisting sleeve. Further, these wrapped grips can become twisted during the wrapping process.

Applicant's U.S. Pat. No. 6,857,971 disclosed a single panel grip which in one embodiment provided the same tackiness and resistance to shock afforded by such grips.

Applicant's U.S. Pat. No. 6,843,732 disclosed multiple segments incorporated into a single panel, which is then applied to the underlisting sleeve.

Applicant's U.S. Patent Publication No. 2007-0004529 disclosed incorporating multiple two layer sheet pieces onto a backing layer.

The present invention relates to an improved grip assembly for golf clubs and other sporting equipment employing handles subject to shock when such devices are impacted.

It is well known that the shock generated by impact between a golf club and a golf ball can adversely affect muscle tissue and arm joints. The energy generated by such impact is usually of high frequency and short duration with rapid decay and which is often known as “impact shock.” Tight grasping of a golf club grip to keep it from slipping in a user's hands contributes to such impact shock.

The Applicant has previously developed resilient grips which successfully reduce or even eliminate impact shock to the muscle and arm joint of the users of golf clubs. See for example U.S. Pat. No. 5,797,813, granted to applicant Aug. 25, 1998. Such earlier grips utilize a polyurethane layer bonded to a felt layer to define a resilient strip, which is spirally wrapped around an underlisting sleeve, with such underlisting sleeve being slipped over the handle portion of a golf club shaft.

A problem encountered with such grips is the tendency of the spirally-wrapped resilient strip to unravel from the golf club handle when a golf club is removed form and inserted into a golf bag. This problem has existed since at least 1923 as evidenced by Howe U.S. Pat. No. 1,528,190 wherein the inventor stated:

-   -   “After using a club, the golfer often throws his club violently         into his bag; in doing so the handle end is of course within the         bag.     -   When the club is thrown into the bag in this way, the end of the         handle rubs along the inside of the bag and frequently results         in stripping the end of the leather beyond the cord wrapping.         Then the cord wrapping will become displaced or broken and it         will be necessary to repair the handle.”

My U.S. Pat. No. 6,386,989 discloses a golf club grip wherein the lower end of the resilient strip is restrained from unraveling from the underlisting sleeve by forming the upper portion of the nipple of the sleeve with a circumferential groove which receives the lowermost edge of the strip, after which an outer peripheral lip defined by the groove is folded upwardly over such lower edge. The lip snugly encompasses the strip's lower edge and retains the lower edge against unraveling from the sleeve and hence the handle of the golf club during play, as well as when a golf club is inserted into and removed from a golf bag.

Applicant has previously developed resilient grips which successfully reduce impact shock to the muscle and arm joints of the user's of golf clubs and also provide a feeling of tackiness between a player's hands and the grip. See for example U.S. Pat. No. 5,797,813 granted to Applicant on Aug. 25, 1998. Such earlier grips utilize a polyurethane-felt strip which is spirally wrapped around an underlisting sleeve that is slipped onto and adhered to a golf club handle. The sides of the strips are formed with overlapping heat depressed recessed reinforcement edges. While such grips have proven satisfactory in reducing impact shock, their fabrication is labor intensive, particularly since the strip must be wrapped manually about the underlisting sleeve within specific pressure parameters. Additionally, it is difficult to accurately align the adjoining side edges of the strip as such strip is being spirally wrapped about underlisting sleeve. The strip of such wrapped grips can become twisted during the wrapping process. This is a particularly difficult problem when wrapping putter grips. These wrapped grips also do not lend themselves to the display of decorative designs.

Despite these improvements, there remains the opportunity for additional grip advances.

SUMMARY OF THE INVENTION

Embodiments of the present disclosure include a tube preferably for use with a golf club grip wherein the tube includes a body having a first end, a second end including a cover, a support surface positioned between the first and second ends and a raised portion. The raised portion extends outwards from the support surface and may be integrally formed with the support surface. The cover may define a substantially closed outer surface and extends outwards from the support surface. The raised portion includes an exposed surface and a connecting surface extending between the support surface and the exposed surface. The raised portion also extends along the body to form a finger zone on the body. There is no slot in the underside of the cover, leaving the support surface adjacent the cover exposed. In some embodiments, the raised portion is integrally formed with the cover such that the exposed support surface adjacent the cover is adjacent the connecting surface of the raised portion.

Embodiments of the present disclosure include a grip preferably for use with a golf club wherein the grip includes a tube having a body with a first end, a second end including a cover, a support surface positioned between the first and second ends and a raised portion extending outwards from the support surface. The raised portion may be integrally formed with the support surface and the cover may define a substantially closed outer surface and may extend outwards from the support surface. The raised portion includes an exposed surface and a connecting surface extending between the support surface and the exposed surface. The raised portion may also extend along the body to form a finger zone on the body. The grip further includes a layered sheet including an inner layer and an outer layer. The sheet is configured to overlay the support surface and not the exposed surface of the raised portion. The layered sheet is wrapped about the tube such that the layered sheet contacts the support surface of the tube and the inner layer of the layered sheet may be adhered to the support surface. The outer surface of the layered sheet and the exposed surface of the raised portion cooperate to define a gripping surface positioned to be gripped by, for example, a golfer. The outer surface of the layered sheet and at least a portion of the outer surface of the cover extend outwardly substantially the same distance. In some embodiments, the raised portion and the cover are integrally formed such that they cooperate to form the end of the grip and the end region of the gripping surface.

The golf club grip of the present invention solves the problem of the upper end of the resilient strip of a golf club grip unraveling from the handle of a golf club during play and particularly when the golf club is removed from and inserted into a golf bag. Such problem is solved by forming the underside of the cap of the underlisting sleeve with a circumferential slot that snugly receives the upper edge of the resilient strip to prevent the strip from unraveling.

These and other features and advantages of the present invention will become apparent from the following detailed description of a preferred embodiment which, taken in conjunction with the accompanying drawings, illustrates by way of example the principles of the invention.

In one embodiment, the golf club grip overcomes the aforementioned disadvantages of existing spirally wrapped grips while providing the same resistance to shock afforded by such grips, as well as providing tackiness and reducing the overall weight of the grip. An embodiment consists of a grip for a golf club comprising a resilient underlisting sleeve having a main portion, a top end, and a bottom end. The sleeve further comprises a cap positioned at the top end which defines an underside portion positioned between the end of the cap and the bottom end of the sleeve. The sleeve also comprises a hole configured to receive the end of a golf club shaft and positioned near the bottom end of the sleeve. The grip further comprises a single panel comprising a top region having skiving along the length of the region, a bottom region, and two side regions. The panel further comprises a configuration corresponding to the exterior shape of the resilient sleeve and an inner layer and an outermost layer, the inner layer comprising one of a fabric and a polymer. The panel is adhered to the underlisting sleeve such that the outermost layer in the top region contacts the underside portion of the cap.

Another embodiment is a method of making a grip for a golf club including the following steps: providing an underlisting sleeve having a main portion, a top end, a bottom end, a cap defining an underside portion and positioned near the top end, and a hole configured to receive the end of a golf club shaft and positioned near the bottom end, providing a single panel having at least an inner layer and an outermost layer, the inner layer comprising one of a fabric and a polymer, configuring the panel to have a top region, a bottom region, and two side regions, further configuring the panel to correspond with the exterior shape of the resilient sleeve, skiving along the length of the top region of the panel, adhering the panel to the underlisting sleeve, and positioning the panel on the underlisting sleeve such that the outermost layer in the top region contacts the underside portion of the cap.

The golf club grip may be manufactured at considerably less cost than existing spirally wrapped grips, since the intensive labor of spirally wrapping a strip around an underlisting sleeve within specific pressure parameters is eliminated. Additionally, the single panel grip will desirably not twist either during manufacture or after it is adhered to an underlisting sleeve. My new grip desirably has an appearance similar to conventional molded rubber grips so as to appeal to professional golfers and low-handicap amateurs, and desirably also provides a greater area for the application of decorative designs.

These and other objects and advantages will become apparent from the following detailed description when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Further objects, features and advantages of the inventions will become apparent from the following detailed description taken in conjunction with the accompanying figures showing illustrative embodiments of the invention, in which:

FIG. 1 is a perspective view of a golf club incorporating a grip according to some embodiments;

FIG. 2 is a front view of a grip according to some embodiments;

FIG. 3 is a rear view of a tube according to some embodiments;

FIG. 4 is a side view of the tube shown in FIG. 3;

FIG. 5 is a front view of the tube shown in FIG. 3;

FIG. 6 is a horizontal sectional view taken along line 6-6 of FIG. 4;

FIG. 7 is a horizontal sectional view taken along line 7-7 of FIG. 5;

FIG. 8 is an enlarged view of the encircled area designated 8 in FIG. 6;

FIG. 9 is a front view of an embodiment of a layered sheet according to some embodiments;

FIG. 10 is a vertical cross-sectional view taken along the line designated 10-10 in FIG. 9;

FIG. 11 is a horizontal cross-sectional view taken along the line designated 11-11 in FIG. 9;

FIG. 12 is a horizontal cross-sectional view showing a mold which may be utilized in forming a layered sheet of a grip according to some embodiments;

FIG. 13 is an enlarged view of the encircled area designated 13 in FIG. 12;

FIG. 14 is an enlarged view of an exemplary pattern that may be formed by the mold shown in FIGS. 12 and 13;

FIG. 15 is an enlarged view of another exemplary pattern that may be formed by the mold shown in FIGS. 12 and 13;

FIG. 16 is a schematic view showing a portion of a method of making a sheet according to some embodiments;

FIG. 17 is a top view of a portion of the schematic view shown in FIG. 16;

FIG. 18 is a schematic view showing an apparatus for use in a portion of a method of making a sheet according to some embodiments;

FIG. 19 is an enlarged view of the encircled area designated 19 in FIG. 17;

FIG. 20 is an enlarged view of the encircled area designated 20 in FIG. 19;

FIG. 21A is a SEM image at 100 times magnification of a cross-section of a sheet made according to a method of some embodiments;

FIG. 21B is a SEM image at 500 times magnification of a portion of the cross-section shown in FIG. 21A;

FIG. 22A is a SEM image at 100 times magnification of a cross-section of a sheet made according to a method of the prior art;

FIG. 22B is a SEM image at 500 times magnification of a portion of the cross-section shown in FIG. 21A;

FIG. 23 is a partial schematic cross-sectional view taken along the line 23-23 in FIG. 19;

FIG. 24 is a partial schematic cross-sectional view of a painted sheet;

FIG. 25 is a front view of a layered sheet of a grip according to some embodiments;

FIG. 26 shows the bottom edge of a layered sheet being skived;

FIG. 27 shows a first side edge of a layered sheet being skived;

FIG. 28 shows a second side edge of the layered sheet shown in FIG. 27 being skived;

FIG. 29 is a rear view showing adhesive being applied to a layered sheet of a grip according to some embodiments;

FIG. 30 is a front view showing adhesive being applied to the exterior of a tube according to some embodiments;

FIG. 31 is a side elevational view showing a step in wrapping and adhering a layered sheet to a tube;

FIG. 32 is a side elevational view showing another step in wrapping a layered sheet around a tube;

FIG. 33 is a side elevational view showing a layered sheet after it has been adhered to a tube according to some embodiments;

FIG. 34 is a horizontal sectional view taken along line 34-34 of FIG. 31;

FIG. 35 is a horizontal sectional view taken along line 35-35 of FIG. 32;

FIG. 36 is a horizontal sectional view taken along line 36-36 of FIG. 33;

FIG. 37 is an enlarged view of the encircled area designated 37 in FIG. 35;

FIG. 38 is an enlarged view of the encircled area designated 38 in FIG. 36;

FIG. 39 illustrates the use of a nozzle in connection with the enlarged view shown in FIG. 38;

FIG. 40 is a partial cross-sectional view taken along the line 40-40 in FIG. 33;

FIG. 41 is a partial cross-sectional view taken along the line 41-41 in FIG. 2;

FIG. 42 illustrates the use of a nozzle in connection with the enlarged view shown in FIG. 41;

FIG. 43 is a side view of a tube according to some embodiments;

FIG. 44 is a horizontal sectional view taken along line 44-44 of FIG. 43;

FIG. 45 is a rear view of a layered sheet of a grip according to some embodiments;

FIG. 46 is a horizontal sectional view of a layered sheet being wrapped around a tube according to some embodiments;

FIG. 47 is a partial cross-sectional view of a layered sheet bonded to a tube and a raised portion thereof according to some embodiments;

FIG. 48 is a broken perspective view showing the upper portion of a spirally-wrapped prior art golf club grip starting to unravel from the handle of a golf club;

FIG. 49 is a top plan view of the golf club grip shown in FIG. 48;

FIG. 50 is a cut-away side view showing a golf club provided with a prior art golf club grip being inserted into a golf bag resulting in the unraveling of FIGS. 48 and 49;

FIG. 51 is a side view of an underlisting sleeve utilized in a spiral-wrap golf club grip embodying the present invention;

FIG. 52 is a vertical sectional view taken in enlarged scale along line 52-52 of FIG. 51;

FIG. 53 is a cross-sectional view showing the upper portion of the underlisting sleeve of FIG. 52;

FIG. 54 is a horizontal view taken along line 54-54 of FIG. 53;

FIG. 55 is a broken top view of a resilient strip of a grip embodying the present invention;

FIG. 56 is a bottom view showing the underside of the grip of FIG. 55;

FIG. 57 is a vertical sectional view taken in enlarged scale along line 57-57 of FIG. 55;

FIG. 58 is a vertical sectional view taken in enlarged scale along line 58-58 of FIG. 55;

FIG. 59 is a broken side elevational view showing the strip of FIGS. 55-57 about to be spirally-wrapped about the underlisting sleeve of FIGS. 51-54;

FIG. 60 is a broken side elevational view taken in enlarged scale showing the leading edge of the resilient strip being manually forced into an upwardly extending circumferential slot formed in the underside of the cap of said underlisting sleeve;

FIG. 61 is broken side elevational view showing the resilient strip being spirally-wrapped about the underlisting sleeve;

FIG. 62 is a broken vertical sectional view taken in enlarged scale along line 62-62 of FIG. 61;

FIGS. 63, 64, and 65 are broken side elevational views showing the lower portion of the resilient sleeve being spirally wrapped around and secured to the lower portion of the underlisting sleeve;

FIG. 66 is a vertical cross-sectional view of grip embodying the present invention;

FIG. 67 is a perspective view of a golf club provided with a polyurethane-EVA single panel grip according to an embodiment of the present invention;

FIG. 68 is a perspective view showing a putter provided with a polyurethane-EVA single panel grip according to an embodiment of the present invention;

FIG. 69 is a front view of the polyurethane-EVA single panel after being press cut to its final working shape;

FIG. 70 is a vertical cross-sectional view taken along the line designated 70-70 of FIG. 69;

FIG. 71 is a horizontal cross-sectional view taken along the line designated 71-71 of FIG. 69;

FIG. 72 is an enlarged view of the encircled area designated 72 in FIG. 71;

FIG. 73 is a side view showing a first mold which may be utilized in forming a polyurethane-EVA single panel grip;

FIG. 74 is a vertical cross-sectional view taken along the line designated 74-74 of FIG. 73;

FIG. 75 is an enlarged view of the encircled area designated 75 in FIG. 73;

FIG. 76 is an enlarged view of the encircled area designated 76 in FIG. 73;

FIG. 77 is an enlarged view of the encircled area designated 77 in FIG. 73;

FIG. 78 is a front view of the polyurethane-EVA single panel after it has been removed from the mold shown in FIG. 73;

FIG. 79 is a front view of the polyurethane-EVA single panel after it has been removed from another version of the mold shown in FIG. 73;

FIG. 80 is a front view of the polyurethane-EVA single panel after it has been removed from another version of the mold shown in FIG. 73;

FIG. 81 is a vertical cross-sectional view taken along the line designated 81-81 of FIG. 78;

FIG. 82 is a side view showing another mold which may be utilized in forming a polyurethane-EVA single panel grip;

FIG. 83 is a vertical cross-sectional view of the mold taken along the line designated 83-83 of FIG. 82;

FIG. 84 is an enlarged view of the encircled area designated 84 in FIG. 82;

FIG. 85 is a front view of the interior surface of the polyurethane-EVA single panel after it has been removed from one version of the mold shown in FIG. 82;

FIG. 86 shows the top and bottom edges of the polyurethane-EVA single panel being skived;

FIG. 87 shows a first side edge of the polyurethane-EVA single panel being skived;

FIG. 88 shows a second side edge of the polyurethane-EVA single panel being skived;

FIG. 89 is a front view of the interior surface of the polyurethane-EVA single panel after the top, bottom and side edges thereof have been skived in the manner depicted in FIGS. 86, 87 and 88;

FIG. 90 is a front view of an underlisting sleeve member of the polyurethane-EVA single panel grip of the present invention;

FIG. 91 is a vertical cross-sectional view taken along the line designated 91-91 of FIG. 90;

FIG. 92 is an enlarged view of the encircled area designated 92 in FIG. 91;

FIG. 93 is an enlarged view of the encircled area designated 93 in FIG. 91;

FIG. 94 is a front view showing one version of adhesive being applied to the exterior surface of the underlisting sleeve;

FIG. 95 is a front view showing one version of adhesive being applied to the interior surface of the polyurethane-EVA single panel;

FIG. 96 is a front view showing a first step in wrapping and adhering the polyurethane-EVA single panel to an underlisting sleeve;

FIG. 97 is a front view showing a second step in wrapping and adhering the polyurethane-EVA single panel to an underlisting sleeve;

FIG. 98 is a front view showing the polyurethane-EVA single panel adhered to an underlisting sleeve;

FIG. 99 is a horizontal cross-sectional view taken along the line designated 99-99 of FIG. 96;

FIG. 100 is a horizontal cross-sectional view taken along the line designated 100-100 of FIG. 97;

FIG. 101 is a horizontal cross-sectional view taken along the line designated 101-101 of FIG. 98;

FIG. 102 an enlarged view of the encircled area designated 102 in FIG. 100;

FIG. 103 an enlarged view of the encircled area designated 103 in FIG. 101 showing a seam between the side edges of one embodiment of the single panel;

FIG. 104 is a side view showing a heat depressed sealing channel being formed along the top portion of the seam shown in FIG. 103;

FIG. 105 is a vertical cross-sectional view taken along the line designated 105-105 of FIG. 104;

FIG. 106 shows the parts of FIG. 105 after the sealing channel has been formed;

FIG. 107 an enlarged view of the encircled area designated 107 in FIG. 106;

FIG. 108 is a front view of a completed polyurethane-EVA single panel grip according to an embodiment of the present invention;

FIG. 109 is a vertical cross-sectional view taken along the line designated 109-109 of FIG. 108;

FIG. 110 is a vertical cross-sectional view taken along the line designated 110-110 of FIG. 108;

FIG. 111 is a broken front view showing a first step in making a modification of the grip of FIG. 108;

FIG. 112 is a broken front view showing a second step in making a modification of the grip of FIG. 108;

FIG. 113 is a horizontal cross-sectional view taken along the line designated 113-113 of FIG. 112;

FIG. 114 an enlarged view of the encircled area designated 48 in FIG. 113;

FIG. 115 is a front view of a polyurethane-EVA single panel grip as in FIG. 98, ready for modification;

FIG. 116 is a broken front view showing a first step in making a modification of the grip of FIG. 115;

FIG. 117 is a broken front view showing a second step in making a modification of the grip of FIG. 115;

FIG. 118 is a front view of a grip made in accordance with FIGS. 115-117;

FIG. 119 is a broken front view showing another modification of the grip shown in FIG. 115;

FIG. 120 is a horizontal cross-sectional view taken along the line designated 120-120 of FIG. 119;

FIG. 121 an enlarged view of the encircled area designated 121 in FIG. 120;

FIG. 122 is a broken front view showing another modification of the grip shown in FIG. 115;

FIG. 123 is a horizontal cross-sectional view taken along the line designated 123-123 of FIG. 122;

FIG. 124 an enlarged view of the encircled area designated 124 in FIG. 123;

FIG. 125 is a side view of a die that can be utilized in modifying embodiments of the present invention;

FIG. 126 is a horizontal cross-sectional view taken along the line designated 126-126 of FIG. 125;

FIG. 127 is a vertical cross-sectional view taken along the line designated 127-127 of FIG. 125;

FIG. 128 an enlarged view of the encircled area designated 128 in FIG. 127;

FIG. 129 is a front view of a grip made in accordance with FIGS. 125-128;

FIG. 130 is a perspective front view of an underlisting sleeve of a putter grip according to an embodiment of the present invention;

FIG. 131 is a side view of the underlisting sleeve of FIG. 130;

FIG. 132 is a horizontal cross-sectional view taken along the line designated 132-132 of FIG. 130;

FIG. 133 is a vertical cross-sectional view taken along the line designated 133-133 of FIG. 131;

FIG. 134 is a vertical cross-sectional view taken along the line designated 134-134 of FIG. 131;

FIG. 135 is a front view of the polyurethane-EVA single panel of a golf club putter grip according to an embodiment of the present invention;

FIG. 136 is a vertical cross-sectional view taken along the line designated 136-136 of FIG. 135;

FIG. 137 is a perspective front view of a completed polyurethane-EVA single panel putter grip according to an embodiment of the present invention;

FIG. 138 is a rear view of the putter grip of FIG. 137; and

FIG. 139 is a horizontal cross-sectional view taken along the line designated 139-139 of FIG. 137.

FIG. 140 is a front view showing the polyurethane-felt single panel adhered to an underlisting sleeve;

FIG. 141 is a horizontal cross-sectional view taken along the line designated 141-141 of FIG. 140;

FIG. 142 is a perspective front view of a completed polyurethane-felt single panel putter grip according to an embodiment of the present invention; and

FIG. 143 is a horizontal cross-sectional view taken along the line designated 143-143 of FIG. 142.

While the subject inventions will now be described in detail with reference to the figures, it is done so in connection with the illustrative embodiments. It is intended that changes and modifications can be made to the described embodiments without departing from the true scope and spirit of the subject inventions.

DETAILED DESCRIPTION

There are numerous embodiments disclosed herein. As one of skill in the art will appreciate, when the specification refers to various features in the context of the “present invention”, it refers to features present in some embodiments of the invention rather than in all iterations of the invention.

FIG. 1 shows one embodiment of a grip G attached to the shaft S of a golf club GC. FIG. 2 shows the grip G in greater detail.

Certain embodiments of grip G include a resilient mounting tube T and a layered member or sheet L wrapped about the tube T. The mounting tube T includes raised portions R which define one or more exposed surfaces E. Desirably tube T includes a tubular body 48 with one or more raised portions R₁, R₂ . . . R_(n) having associated exposed surfaces E₁, E₂ . . . E_(n). In the illustrated embodiment, tube T includes two raised portions R₁ and R₂ with exposed surfaces E₁ and E₂. The grip defines a gripping surface GS. The gripping surface GS may include an outer surface of a layered sheet L and exposed surfaces E₁ and E₂ of raised portions R₁ and R₂ of tube T. (See, e.g., FIG. 2).

More particularly, referring to FIGS. 3 through 8, there is shown one embodiment of the resilient tube T. During the manufacture of a grip G, tube T may be mounted on a mandrel (not shown) as known to those of skill in the art. Tube T includes a first end 2 and a second end 4. Tube T further includes a hollow inner cavity 3 configured to correspond to the outer shape of the shaft GS of a golf club GC. An opening 6 and a ring 8 are formed at the first end 2 while the second end 4 of tube T is formed with a cover 10, which in some embodiments substantially closes the second end 4. Tube T has a support surface 12 extending generally between cover 10 and ring 8. In some embodiments, tube T is formed of a resilient material such as a natural or synthetic rubber or plastic. For example, the rubber might include a mixture of synthetic rubber, for example EPDM (Ethylene Propylene Diene Monomer) and natural rubber. Other examples include TPE (Thermoplastic Elastomer), TPR (Thermoplastic Rubber), TPU (Thermoplastic Polyurethane), and TPV (Thermoplastic Vulcanizate). In some embodiments, the ratio of synthetic rubber to natural rubber is approximately 2 to 3.

As known to those of skill in the art, tube T may be formed in a mold (not shown). In some embodiments, raised portions R₁ and R₂ are integrally formed on tubular body 48. In such instances, tubular body 48 and raised portions R₁ and R₂ may comprise the same material. If this is the case, forming raised portions R₁ and R₂ merely requires creating the inverse of raised portions R₁ and R₂ in the mold. In such cases, the material is selected to enhance the properties desired for raised portions R₁ and R₂ while balancing the desired properties for tubular body 48. In some instances, it may be desired to control the durometer, tackiness, resistance to torque, durability, color, or other property of raised portions R₁ and R₂ to enhance certain properties of completed grip G.

As shown in FIG. 7, a connecting surface 46 a forms an angle α₁ with a line tangent to the intersection of connecting surface 46 a of raised portion R₁ and support surface 12 of tube T. In general, connecting surface 46 desirably extends between support surface 12 and exposed surface E of raised portion R and forms an angle α. In some embodiments, angle α is in the range of approximately 5 and 175 degrees. In some embodiments, angle α is in the range of approximately 5 and 90 degrees. In some embodiments, angle α is in the range of approximately 90 and 175 degrees. In some embodiments, for example the embodiment shown in FIG. 7, angle α is approximately 90 degrees.

In general, raised portion R extends a width w around the circumference of body 48 of tube T. Width w may be constant along tube T, for example if raised portion R forms a rectangular shape. Alternatively, width w may vary along tube T. In some embodiments, width w may extend to a maximum distance around the circumference of tube T (expressed as a percentage of the circumference of the body 48 of tube T) in the range of approximately 25% to 75%. In some embodiments, width w may extend to a maximum in the range of approximately 5% to 25%. In some embodiments, width w may extend to a maximum in the range of approximately 75% to 100%. In some embodiments, width w may vary along the longitudinal length of R. For example, in the illustrated embodiment, raised portion R₁ defines an elliptical shape with a width wi starting near zero and widening to approximately 50% and narrowing back to near zero along tube T from first end 2 to second end 4. Width w need not vary consistently along tube T. Referring to FIGS. 3 through 5, in the illustrated embodiment raised portion R₁ is configured to form a thumb zone TZ in the gripping surface GS. Thumb zone TZ is shown on the front of tube T to accommodate a user's thumbs when that user employs a traditional golf grip with some or all of the fingers overlapping and/or interlocking on the back of the grip and the thumbs resting on or near the front of the grip. As will be understood by one of skill in the art, thumb zone TZ may be placed in other areas of gripping surface GS to accommodate different grips.

In some embodiments raised portion R₁ extends at least the length of an adult's finger pad in a circumferential direction. In some embodiments, raised portion R_(i) extends at least the length of an adult's finger pad along the longitudinal direction. In some embodiments, raised portion R₁ extends at least the length of two adult finger pads along the longitudinal direction. For purposes of this application, the length of an adult's finger pad is defined as being one inch.

In some embodiments, the upper portion of raised portion R₂ adjacent cover 10 extends a width w₂ of 100% of the circumference of tube T. In some such embodiments, raised portion R₂ is formed integrally with cover 10 such that the transition between cover 10 and raised portion R₂ is substantially smooth. As shown in, for example, FIGS. 3 through 5, raised portion R₂ may extend further down the length of tube T from second end 4 toward first end 2 on the back of tube T than it does on the front of tube T. As described in greater detail below, such an extended region can provide a finger zone FZ in the gripping surface GS with characteristics different than those provided by the layered sheet L in other regions of the gripping surface GS. In some embodiments, finger zone FZ of raised portion R₂ extends at least the width of 4 adult finger pads along tube T from second end 4 toward first end 2. For purposes of this application, the width of an adult finger pad is defined as being one half inch.

In some embodiments, the upper portion of raised portion R₂ in the front of tube T is configured to form a palm zone PZ in gripping surface GS. In some embodiments, palm zone PZ of raised portion R₂ extends at least the width of one adult finger pad along tube T from second end 4 toward first end 2. In some embodiments, palm zone PZ extends at least the width of 2 or more adult finger pads along tube T from second end 4 toward first end 2.

Friction may be enhanced on raised portion R by forming ridges or valleys in various patterns 47 on surface E of raised portion R. As shown in, for example, FIG. 5, different patterns 47 a and 47 b may be used. The patterns may be different on different raised portions or the same or similar patterns may be used. In some embodiments, the patterns are formed as raised portion R is molded. In other embodiments, the patterns are applied by altering surface E of portion R after the molding process, such as by grinding surface E.

In some embodiments, one or more of the raised portions R may be formed separately from tubular body 48 and attached to tubular body 48 through bonding, adhesive or other mechanisms known to those of skill in the art to form tube T. Separately forming a portion R may facilitate using a different material to form the particular raised portion R than is used to form tubular body 48. In embodiments where multiple raised portions are desired, separately forming one or more of the portions allows for a wide variety of different materials to be incorporated into the grip. It is also possible for some portions to be formed integrally with tubular body 48 while others are attached after tube T is molded. Raised portion R is generally configured with a thickness t_(R) as shown in FIG. 7.

Referring to FIG. 8, ring 8 of tube T may be formed with an upwardly extending slot 30 defined by a portion 32 of support surface 12 of tube T and lip 34 extending upwardly from ring 8 and preferably wrapping substantially circumferentially around tube T. Lip 34 defines an inner surface 36 facing tube T, an upper surface 38 facing upward from ring 8, and an outer surface 40 facing away from support surface 12 of tube T. Upwardly extending lip 34 extends over portion 32 of support surface 12 of tube T. The lower-most portion of slot 30 is defined by an inner, lower, upwardly facing surface 42. Though lip 34 may flex outward from tube T, in many embodiments it resists remaining in a fully flexed position in which it lays flat, thereby fully exposing tube T support surface 12. In alternative embodiments, outer surface 40 tapers toward inner surface 36, or inner surface 36 tapers toward outer surface 40 such that upper surface 38 is comparatively narrow and in some embodiments is an annular point extending substantially circumferentially around tube T. Slot 30 receives, for example, the bottom region of a layered sheet L. To assist in installation of a layered sheet L, in some embodiments tube T will be formed with centering notches (not shown) disposed on an outer surface of cover 10, ring 8 and/or both.

Referring now to FIGS. 9 through 15 a layered sheet L for use with tube T is described. Various aspects and attributes of layered sheet L may be combined from the disclosure below. Generally, layered sheet L has a thickness ti, (FIG. 11) and includes an outer surface 174 and an inner layer 50 having its outer face bonded to the inner face of an outer layer 52. Outer layer 52, in some embodiments, comprises a polymer. In some embodiments, that polymer comprises polyurethane. Additional materials such as waterproofing coatings may be incorporated on outer surface 174. Similarly, other materials such as fabric meshes may be incorporated into outer layer 52. Inner layer 50 may be fabricated of a fibrous material including, for example, wool, polyester, nylon, or mixtures thereof. In certain embodiments, a nylon polyester fibrous material such as felt is used. During the manufacturing process, some of outer layer 52 may permeate inner layer 50. For example, when polyurethane is used in the outer layer and a fibrous material is used in the inner layer, some polyurethane may permeate the fibrous layer. In another embodiment, inner layer 50 may comprise a polymer, such as, for example, ethylene vinyl acetate (EVA).

Outer layer 52 may provide a cushioned grasp for a golfer's hands on a golf club and may enhance the golfer's grip by providing increased tackiness between the golfer's hands and the grip. Inner layer 50 may provide strength to outer layer 52 and serve as a means for attaching the bonded-together layered sheet L to the tube T.

The outer surface of inner layer 50 in some embodiments is bonded to the inner surface of outer layer 52. For purposes of this disclosure, the definition of bonding is intended to have a broad meaning, including commonly understood definitions of bonding, adhering, fixing, attaching, sewing, coupling, and gluing. As will be appreciated by those of skill in the art, the foregoing terms have their ordinary meaning. In some embodiments, the material used in the outer layer may penetrate some distance into the inner layer. When polyurethane is used in outer layer 52, such polyurethane is preferably coagulated to define pores, as shown, for example, in FIG. 21A. The polyurethane may be coagulated and bonded directly to inner layer 50 or may be first coagulated on an intermediary layer (not shown) and later attached to inner layer 50.

Layered sheet L may include centering notches (not shown) positioned at the top region A and/or the bottom region B of the layered sheet indicating a middle point between a first side region C₁ and a second side region C₂. Centering notches may assist in the application of layered sheet L to tube T to form grip G. Layered sheet L is configured to correspond with tube T and, in particular, has been adapted to correspond with raised portions R₁ and R₂. Layered sheet L includes cut-out 184. Cut-out 184 is substantially elliptical in shape defined by edge 190 and has its major axis substantially parallel to the longitudinal axis of tube T. As such, cut-out 184 corresponds to the overall shape of raised portion R₁. Top region A is defined by edge 192 shaped to correspond to the lower edge of raised portion R₂.

Referring now to FIGS. 12 through 15, there is shown a mold M which is utilized to form a friction enhancing pattern 54 as known to those of skill in the art. Friction enhancing pattern 54 may take any of a number of forms or combinations thereof. For example, two such patterns 54 a and 54 b are shown in FIGS. 14 and 15, respectively. In alternative embodiments, mold M forms logos, designs, insignias and other marks (not shown) in outer layer 52. Mold M in one embodiment includes a heated platen 56 formed with a cavity 58. Platen 56 is provided with depending protrusions 60 that engage outer surface 174 of layered sheet L so as to form depressed friction enhancing pattern 54, as seen in FIG. 13. Friction enhancing pattern 54 may also be applied to the other layered sheets described below.

In alternative embodiments, other patterns may be formed on or in outer layer 52. These patterns may also incorporate stamped visual indicia, including designs or logos, on layered sheet L. In some embodiments, stamped visual indicia is ink stamped onto outer layer 52 using a suitable ink known to those of skill in the art. The ink in some implementations is waterproof, heat resistant and formulated to resist degradation when coming into contact with a lubrication fluid or solvent which may be used to apply completed grip G over the end of golf club shaft CS (FIG. 1). It is to be understood that many other patterns and stamps may be used with other embodiments of the grip disclosed herein.

Though not shown in the figures, a multi-segment single panel as disclosed in U.S. Pat. No. 6,843,732, incorporated herein in its entirety, may also be applied to tube T as described herein. In some embodiments, raised portion R on tube T facilitates attachment of the multi-segment single panel disclosed in the '732 patent to tube T without first skiving some or all of the outer regions of the panel. Similarly, a layered sheet including cutouts and corresponding layered inserts as disclosed in U.S. patent application Ser. No. 11/417,643, incorporated herein in its entirety, may also be applied to tube T as described herein.

Referring to FIGS. 16 through 25, there is shown a method of forming a sheet 80 having an inner layer and an outer layer that can be shaped into another layered sheet L2 (FIG. 25). Referring to the upper right-hand portion of FIG. 16, there is shown a supply roll 82 of substrate 84. Substrate 84 has a top surface 86 and a bottom surface 88. In some embodiments, substrate 84 includes a fibrous material, for example felt or other fabrics, which may include wool, polyester, nylon, or mixtures thereof. In one embodiment, substrate 84 comprises a fabric including nylon and polyester. From the supply roll 82, substrate 84 is moved horizontally to the left below a first polyurethane dispensing machine 90. The first dispensing machine 90 preferably continually deposits a first region of liquid polyurethane 92, for example polyester or polyether dissolved in dimethyl formamide (DMF), onto top surface 86 of substrate 84 to form first web 94. The first dispensing machine 90 preferably uses a nozzle, sprayer or the like to deposit the first polyurethane region 92 and preferably uses a blade to control the thickness of the first polyurethane region 92. First polyurethane region 92 has a top surface 96 and a bottom surface 98.

As first web 94 continues to the left from first dispensing machine 90, a second polyurethane dispensing machine 100 deposits a second liquid polyurethane region 102 onto at least a portion of top surface 96 of first polyurethane region 92 to form a second web 104. Second polyurethane region 102 has a top surface 106. Second web 104 is then moved into a water bath 108 contained in a first tank 110. As second web 104 is immersed in water bath 108, polyurethanes 92 and 102 will coagulate so as to form a coagulated region 112 on substrate 84. Coagulated region 112 and substrate 84 cooperate to form sheet 80 wherein the coagulated region forms the outer layer and the substrate forms the inner layer. Coagulated region 112 has a top surface 144 and a bottom surface 114.

As is known, the coagulation time of the polyurethane will be determined by the desired thickness of coagulated region 112, with a thin region requiring less time to coagulate than a thick region. In some embodiments, the coagulation process bonds bottom surface 114 of coagulated region 112 to top surface 86 of substrate 84 so as to fix coagulated region 112 to substrate 84. This bond interface 116 is shown in FIG. 21A. A pair of rollers 118 and 120 are positioned within tank 110 to carry sheet 80 horizontally and then upwardly out of water bath 108 over roller 122. Sheet 80 is then moved horizontally to the right between a pair of squeezing rollers 124. These squeezing rollers 124 compress sheet 80 so as to force a major portion of the DMF disposed within pores 126 downwardly through substrate 84. Referring to FIG. 21A, the bottom end of a sufficient number of the pores are in contact with top surface 86 of substrate 84 to permit fluid flow from the pores through substrate 84. Referring again to FIG. 16, sheet 80 is then moved downwardly through one or more cleaning water bath tanks 128 (only one of which is shown), wherein the temperature of the water is sufficiently high to displace more DMF from the pores, with such DMF being replaced by water 130 contained in tank 128. From tank 128, sheet 80 passes through another pair of squeezing rollers 132 to squeeze more of the DMF out of the pores to be replaced with water 130. In practice, it may be necessary to utilize four or five cleaning baths to remove a desired amount of DMF from the pores. From the last water bath, sheet 80 is passed through a heating chamber (not shown) which drives out any water remaining within pores 126 so that such water is replaced by air.

In another embodiment (not shown), substrate 84 includes a flexible temporary support for the polyurethane during the wet coagulation process described above. Such a temporary support would be configured to be removed from bottom surface 114 of coagulated polyurethane region 112 after sheet 80 is formed. In such an embodiment, bond interface 116 is desirably relatively weak to facilitate separation of coagulated region 112 from substrate 84. One temporary support includes a smooth, flexible nylon cloth and is available from the Ho Ya Electric Bond Factory, Xin Xing Ind. Area. Xin Feng W. Rd., Shi Jie Town Dong Guan City, Guan Dong Province, China. Other materials include fluid-permeable textiles such as cotton or a synthetic cloth such as polyester. Generally, the temporary support would have the fluid-passing characteristics and smooth top surface of nylon cloth allowing the DMF and water to be squeezed out of the polyurethane pores and allowing the coagulated polyurethane to be readily stripped off such temporary support. Removing substrate 84 from coagulated polyurethane region 112 provides for use of coagulated polyurethane region 112 alone or provides the opportunity to use an alternative substrate. For example, it is possible to replace the fabric substrate with a polymer substrate such as ethylene-vinyl acetate (EVA). The EVA substrate may include an adhesive coating to bond the EVA substrate to coagulated polyurethane region 112. EVA having an adhesive coating covered by a protective paper is sold by the aforementioned Ho Ya Electric Bond Factory.

Referring now to FIG. 18, a schematic illustration of second dispensing machine 100 is shown. In FIG. 18, dispensing machine 100 includes a first housing 134 having a first dispensing nozzle 136. Housing 134 is connected to perpendicular rail 138 extending along the Y axis as illustrated. Rail 138, in turn, is connected to parallel rails 140 extending along the X axis as illustrated. Dispensing machine 100 is configured to allow first web 94 of substrate 84 and first polyurethane region 92 to pass beneath nozzle 136, preferably at a constant pace, along the X axis (see FIGS. 16 and 17). First polyurethane region 92 may provide a base region for the second polyurethane region 102. In some regions, second polyurethane region 102 may extend completely through first polyurethane region 92 to be in contact with substrate 84. Dispensing machine 100 is preferably further configured to move nozzle 136 in one or both of the X and Y directions. In addition, nozzle 136 may be configured to start and stop depositing second polyurethane 102 as desired. The movement of nozzle 136 in the X and Y directions and the start/stop feature of the nozzle 136 provides for the ability to create a unique appearance which may include random or semi-random patterns 142 in second web 104 and, in turn, in sheet 80 (see FIG. 17). In other embodiments, web 94 is moved beneath a stationary nozzle 136 to create a pattern. For example, nozzle 136 could be fixed along the X axis and the pace with which web 94 is moved under nozzle 136 can be varied. Similarly, nozzle 136 could be fixed along the Y axis and web 94 can be shifted along the Y axis instead. Alternatively, nozzle 136 can be moved in both directions.

In other embodiments (not shown), dispensing machine 100 may include two, three or more nozzles for dispensing third, fourth, etc. polyurethane regions. Such additional nozzles may be included in the same housing, separate housings or a combination thereof. It is also possible to include additional dispensing machines on separate rails to introduce still further variation in the application of the polyurethane regions.

Referring now to FIG. 19, there is shown an enlarged view of pattern 142 formed in coagulated polyurethane region 112 of sheet 80. Generally, top surface 144 of coagulated region 112 includes pattern 142 because first polyurethane 92 and second polyurethane 102 each include at least one contrasting characteristic. In the illustrated embodiment, the contrasting characteristic is color. However, other contrasting characteristics, or combinations thereof, could be incorporated to create the pattern such as contrasting durometers or levels of tackiness. In the figures, first polyurethane 92 defines a first color 146 and second polyurethane 102 defines a second color 148. As shown in greater detail in FIG. 20, pattern 142 on top surface 144 of coagulated region 112 includes a first region 150 and a second region 152 defined by first color 146 of first polyurethane 92 and second color 148 of second polyurethane 102, respectively.

As described above, the two polyurethanes 92 and 102 are coagulated onto substrate 84 in first water bath 108. The application of second polyurethane 102 onto a portion of top surface 96 of first polyurethane 92 prior to coagulation allows for the polyurethanes to mix and integrate below top surface 96 of the first polyurethane region such that coagulation of the polyurethanes forms the single coagulated region 112 (see FIGS. 21A and 21B). Despite the mixing of the two polyurethanes prior to coagulation, and the integration of the two polyurethanes during coagulation, each of the polyurethanes substantially maintains its original characteristics. The contrast in one or more characteristics of the polyurethanes creates pattern 142. Though the characteristics remain substantially distinct, there may be some blending along the interface of the two polyurethanes.

In the illustrated embodiment, top surface 96 of first polyurethane region 92 cooperates with top surface 106 of second polyurethane region 102 to form substantially smooth top surface 144 of coagulated region 112. Contrasting colors 146 and 148 on surface 144 cooperate to create pattern 142. If the first polyurethane is red and the second polyurethane is white, the process discussed above would result in a coagulated polyurethane region with distinct red and white regions, rather than a single blended pink region. Though the contrasting characteristics of first 92 and second 102 polyurethanes remain substantially distinct, the polyurethane structure below top surface 144 is preferably seamless between the different polyurethanes with a preferably continuous pore structure throughout (see FIGS. 21A and 21B).

FIG. 21A is a 100 times magnification of a cross-section of a sample coagulated sheet 80 taken along the line 21-21 in FIG. 20. FIG. 21A shows substrate 84, in the sample a polyester nylon fabric, with its top surface 86 bonded to bottom surface 114 of coagulated polyurethane region 112 along bond interface 116. Top surface 144 is generally smooth. The structure is desirably substantially seamless on both the top surface 144 between first region 150 and second region 152 and substantially seamless inside coagulated region 112 where first polyurethane 92 interfaces with second polyurethane 102. It is apparent that the structure is not just seamless and not just coagulated, but the two polymers polymerize with each other to form coagulated region 112. Accordingly, in the illustrated embodiment coagulated region 112 is a polymerized region. Coagulated region 112 preferably includes a plurality of generally vertically extending pores 126, top surface 144, and bottom surface 114. Pores 126 generally form substantially throughout coagulated region 112 including in the regions where first polyurethane 92 interfaces with second polyurethane 102 between top 144 and bottom 114 surfaces. Though polyurethane is preferred to form the coagulated region, other liquid polymers having contrasting characteristics may be used. Generally, the polymers will be combined while in their liquid states and allowed to polymerize together. As the polymers polymerize together, the structure of polymerized region 112 will preferably be seamless while maintaining the contrasting characteristics at least on outer surface 144 of polymerized region 112.

FIG. 21B is a 500 times magnification of a portion of the cross-section shown in FIG. 21A. As is apparent from the figures, first 92 and second 102 polyurethanes are coagulated together to form coagulated region 112 with a substantially seamless structure between first color region 150 and second color region 152 and between the polyurethanes inside coagulated region 112.

FIGS. 21A and 21B may be contrasted with a prior art method of using paint to create a sheet with multiple colors, as shown in FIGS. 22A and 22B. In the prior art, a single polyurethane region 154 is coagulated onto a substrate 156 to form a sheet 158 including a coagulated region 160 having a top surface 168 and a bottom surface 170. To achieve regions of different color, a paint 162 having a top surface 164 and a bottom surface 166 would be applied to top surface 168 of coagulated polyurethane region 160 where desired. The polyurethane was coagulated prior to application of the paint and the paint would form a thin separate region over the surface of the coagulated polyurethane.

The prior art method of coating a coagulated region of polyurethane 160 with paint 162 alters the characteristics of sheet 158. As shown in FIG. 22A and in greater detail in FIG. 22B, paint 162 did not integrate with polyurethane region 154. Rather, bottom surface 166 of paint 162 bonds to top surface 168 of polyurethane region 154. In embodiments known to the Applicant, the paint coating the surface had different tactile characteristics from the polyurethane it coated, including different levels of tackiness or durometer. For example, painted grips are generally less tacky in the region covered by paint than in the unpainted regions of polyurethane. In addition, during use, the paint on the polyurethane may wear off giving the grip a weathered or worn appearance. Though valuable and unique, Applicant's other solutions for introducing contrasting characteristics (including the use of multiple sheets, strips and/or inserts) result in seams between the various components.

Embodiments created according to the above description allow for the manufacture of grips having regions of contrasting characteristics wherein the structure of the region is seamless. For example, a red polyurethane having a desired level of tackiness and durometer may be used in conjunction with a blue polyurethane having the same desired level of tackiness and durometer. The sheet formed from the two materials would include a uniquely colored pattern and a seamless structure having a substantially uniform level of tackiness and durometer.

Referring now to FIG. 23, there is shown a partial schematic cross-sectional view of sheet 112 taken along the line 23-23 in FIG. 19. Contrasting regions 150 and 152 are visible on top surface 144. Due to the movement of nozzle 136 relative to web 94 during the application of second polyurethane 102 onto top surface 96 of first polyurethane 92, as discussed above, differing amounts of second polyurethane 102 are applied in different areas or regions. As the polyurethanes mix, second polyurethane 102 settles into first polyurethane 92.

After water bath 108, coagulated region 112 defines a total thickness t_(PolyT) between its top surface 144 and its bottom surface 114. In various regions, second polyurethane 102 extends from top surface 144 into coagulated region 112 with a thickness t_(Poly2). The ratio of t_(Poly2) to t_(PolT) may vary, depending on a number of factors including the speed with which web 94 passes below nozzle 136, the flow rate of second polyurethane 102 from nozzle 136, and the rate of movement of nozzle 136 in the X and Y directions. In some embodiments, the maximum and, preferably, the average ratio of t_(Poly2) to t_(PolyT) in some regions is at least 1 to 15, 1 to 10, 1 to 5, 1 to 4, 1 to 3, and/or 1 to 2. In some regions, the ratio is 1 to 1 where second polyurethane 102 extends from top surface 144 to bottom surface 114. In some embodiments, the ratio varies in different regions of sheet 80.

As discussed above, coagulated region 112 is generally porous. This porous region has a total thickness t_(PorousT) between top surface 144 and bottom surface 114 of coagulated region 112. In various regions, second polyurethane 102 extends from top surface 144 into porous coagulated region 112 with a maximum thickness t_(Porous2). The ratio of t_(Porous2) to t_(PorousT) may vary. In some embodiments, the maximum and, preferably, the average ratio of t_(Porous2) to t_(PorousT) in some regions is at least 1 to 50, 1 to 40, 1 to 30, 1 to 20, 1 to 15, 1 to 10, 1 to 5, 1 to 4, 1 to 3, and/or 1 to 2. In some regions, the ratio is 1 to 1 where second polyurethane 102 extends through porous coagulated region 112 from top surface 144 to bottom surface 114. In some embodiments, the ratio varies in different regions of sheet 80.

Pattern 142 shown in the figures is an example of the patterns achievable with Applicant's method of making the polyurethane sheet. Other patterns are also possible. For example, in some embodiments, nozzle 136 is held steady as second polyurethane 102 is applied to web 94 to create a solid band of second polyurethane 102 across upper surface 96 of first polyurethane 92. Depending on how sheet 80 is formed into layered sheet L2, the band may extend horizontally, vertically, or at an angle on layered sheet L2.

In some embodiments, top surface 96 of first polyurethane region 92 forms substantially all of top surface 144 of coagulated region 112. In such embodiments, relatively smaller quantities of second polyurethane 102 may be applied prior to the coagulation process. In other embodiments, top surface 106 of second polyurethane 102 forms substantially all of top surface 144 of coagulated region 112. In such embodiments, relatively large quantities of second polyurethane 102 may be applied prior to the coagulation process. Embodiments of the present inventions may include different regions of similar patterns. In some, the pattern may be repeated and positioned such that layered sheet L2 formed from the sheet includes at least three regions having contrasting characteristics, such as colors. In some embodiments, layered sheet L2 may be formed with at least 5 regions of contrasting characteristics. In some, there may be at least 7 regions of contrasting characteristics. In some, there may be 10 or more regions of contrasting characteristics. These regions of contrasting characteristics may be arranged throughout top surface 144 of coagulated region 112 of layered sheet L2, whether across the width of layered sheet L2, along the length of layered sheet L2, or in a combination of the two.

Referring now to FIG. 24, there is shown a partial schematic cross-sectional view of sheet 158 shown in FIGS. 22A and 22B. Coagulated region 160 is porous and includes generally smooth top surface 168 and bottom surface 170. Top surface 168 may include one or more irregularities 172 which may extend downward into coagulated region 160. Paint 162 is applied over top surface 168 of coagulated region 160. Due to irregularities 172 in top surface 168 of coagulated region 160, paint 162 may extend into coagulated region 160 with a thickness t_(Porous2). Though unclear, the ratio of t_(Porous2) to t_(PorousT) shown in FIG. 22B appears to be no more than 1 to 100. Thus, if the paint was a second polymer applied to the surface of a coagulated region, the ratio of t_(Porous2) to t_(PorousT) of a paint covered sheet is far from the 1 to 50 ratio discussed above.

As shown in FIG. 25, sheet 80 may be formed into layered sheet L2. In some embodiments, layered sheet L2 is die cut from sheet 80. As will be understood by those of skill in the art, sheet 80 may be formed into any of a number of shapes, including strips, panels, inserts, or panels with cut-outs as may be appropriate for the particular application.

Like layered sheet L described above, layered sheet L2 includes a top surface 174, a top region A, a bottom region B, a first side region C₁, and a second side region C₂. A line drawn from top region A to bottom region B on at least a portion of top surface 174 preferably crosses multiple regions of polyurethane having a different characteristic. In some embodiments, layered sheet L2 may include at least 2, at least 3, at least 5, at least 7, or at least 10 regions having a different characteristic along the line drawn from top region A to bottom region B on at least a portion of top surface 174. In some embodiments, layered sheet L2 may include in the range of between 2 and 500 regions of at least one different characteristic along the line. It should be understood that the different characteristics of the regions may be alternating two or more colors along the line. Alternatively, the different characteristics of the regions may be alternating levels of other characteristics such as tackiness or durometer along the line.

Similarly, a line drawn from first side region C₁ to second side region C₂ on at least a portion of top surface 174 also will preferably cross multiple regions having different characteristics. In some embodiments, layered sheet L2 may include at least 2, at least 3, at least 5, at least 7, or at least 10 regions having a different characteristic along the line drawn from first side region C₁ to second side region C₂ on at least a portion of top surface 174. In some embodiments, layered sheet L2 may include in the range of between 2 and 500 regions of at least one different characteristic along the line.

Likewise, a line drawn into layered sheet L2 from top surface 174 to bottom surface 114 of coagulated region 112 may cross multiple regions. In some embodiments, layered sheet L2 may include at least 2, at least 3, at least 5, at least 7, or at least 10 regions having different characteristics along the line drawn from its top surface 174 to bottom surface 114 of coagulated region 112. In some embodiments, layered sheet L2 may include in the range of between 2 and 50 regions of at least one different characteristic along the line.

As will be understood by those of skill in the art, features of layered sheet L2 may be combined with features of layered sheet L discussed above as desired. For example, as discussed above with respect to the other layered sheets, layered sheet L2 may be further enhanced with a friction enhancing pattern.

FIG. 26 illustrates another step in the manufacture of embodiments of grip G. Layered sheet L is illustrated, but one of skill in the art will understand that similar steps may be taken with layered sheet L2. In some embodiments, bottom region B of layered sheet L is skived. Generally, top region A need not be skived as raised portion R₂ of tube T includes substantially axially extending surfaces 46 b which engage top region A when layered sheet L is attached to tube T. It will be noted that, in some embodiments not shown, top region A of layered sheet L can be skived at various angles to accommodate different angles α₂ of surface 46 b as desired.

FIGS. 27 and 28 illustrate another skiving step in the manufacture of embodiments of grip G. Side regions C₁ and C₂ are shown being skived such that they are substantially parallel to each other. Skiving side regions C₁ and C₂ in such a manner may facilitate the attachment of layered sheet L to tube T in certain embodiments as described in greater detail below. Other possible skiving configurations are possible in addition to leaving the side regions unskived.

Referring generally to the layered sheets disclosed herein, top surface 174 of layered sheet L is in direct contact with the hand of the user using a grip G. However, as one of skill in the art would appreciate, an additional coating region over layered sheet L may be included. It should be understood that the top surface of a grip embodying the disclosure presented above may also be coated, in whole or in part, by means of a brush, nozzle, spray or the like with a thin region of polyurethane and/or other material (not shown) to, for example, protect such surface, add tackiness thereto, and/or increase the durability thereof. The additional coating region is preferably transparent, or semi-transparent, such that some or all of any visual pattern on the outer surface of layered sheet L remains visible. The additional coating region may be somewhat opaque, as long as a portion of the layered sheet L is observable through the additional coating region. The additional coating region may be incorporated into a previously formed grip G or may be applied to the layered sheet L prior to attachment to tube T. If used, the additional coating region would be in direct contact with the user's hand rather than the top surface of the layered sheet. However, even when an additional coating region is included, the top surface of the layered sheet L is considered to be the top surface of the grip G. If an additional coating region is included over the top surface of the grip, this region may also be further enhanced with a friction enhancing pattern as discussed herein.

Referring now to FIGS. 29 through 42, layered sheet L is shown being applied to tube T to form grip G. In FIG. 29 the inner surface of layer 50 is shown receiving an adhesive 180 by means of a nozzle, brush or the like. In FIG. 30 support surface 12 of tube T is shown receiving an adhesive 180 by means of a nozzle, brush or the like. In some embodiments, adhesive 180 is applied to either layered sheet L or tube T.

FIGS. 31 through 42 shows the layered sheet L being wrapped around and adhered to tube T. Combined layered sheet L and tube T form grip G (FIG. 33). As the manufacturing process progresses, tube T will generally be temporarily supported on a collapsible mandrel (not shown) in a conventional manner. During the wrapping operation, bottom region B of layered sheet L will desirably be manually inserted within slot 30 of ring 8. Raised portion R₁ desirably fits within cut-out 184 and is desirably substantially engaged by edge 190 of cut-out 184. Top region A, defined in part by edge 192, is configured to correspond to raised portion R₂. When layered sheet L is wrapped about support surface 12, raised portion R₂ desirably engages edge 192 in the upper portion of the grip G.

In some embodiments, side regions C₁ and C₂ cooperate to form a seam 200 extending generally along the longitudinal axis of tube T. As shown in FIGS. 31 through 39, in some embodiments the side regions C₁ and C₂ are skived in a substantially parallel fashion such that they overlap along the seam 200. In such embodiments, inner layer 50 of side region C₁ preferably corresponds to inner layer 50 of side region C₂ and outer layer 52 of side region C₁ preferably corresponds to outer layer 52 of side region C₂ to form a strong and relatively smooth seam. Other possible seams 200 may be formed. For example, un-skived side regions C₁ and C₂ may be adhered or bonded together. Alternatively, side regions C₁ and C₂ may be stitched together to form the seam 200. In some embodiments, side regions C₁ and C₂ are skived from the center of layered sheet L toward the outer regions of layered sheet L in an anti-parallel fashion and subsequently joined to form seam 200. Such skiving may start at inner layer 50 and extend through outer layer 52, leaving a thin layer of outer layer 52 at the outer portion of side regions C₁ and C₂. In some embodiments, a groove (not shown) may be formed along seam 200 to further enhance seam 200. In some embodiments, seam 200 may include, in addition to adhesive 180, a deposit of polyurethane 202 to assist in bonding or adhering layered sheet L, and in particular outer layers 52 of layered sheet L. Such polyurethane 202 may be deposited with a nozzle or other means known to those of skill in the art (see, e.g., FIG. 39). After the polyurethane hardens, in some embodiments the polyurethane may be buffed by a suitable brush or the like to smoothly blend the surface of the grip while in other embodiments, the polyurethane is not buffed.

Gripping surface GS includes outer surface 174 of layered sheet L, exposed surface E₁ and exposed surface E₂. In general, in embodiments layered sheet L is wrapped around tube T such that layered sheet L abuts connecting surface 46 of raised portion R at an intersection 178, wherein at least a portion of inner layer 50 and/or at least a portion of outer layer 52 abut connecting surface 46 of raised portion R. Desirably, inner layer 50 of layered sheet L is further adhered to support surface 12 of tube T₁.

As shown, for example in FIGS. 40 through 42, inner layer 50 is desirably adhered or bonded to support surface 12 and to connecting surfaces 46 a and 46 b of raised portions R₁ and R₂. Outer layer 52 is also desirably adhered or bonded to connecting surfaces 46 a and 46 b of raised portions R₁ and R₂. Layered sheet L will be adhered to the raised portion R by one or more suitable adhesives 180. A suitable adhesive has a mixture of AD-86 (Toluene, 35%; Methyl Ethyl Ketone, 50%; Polyurethane, 15%) and AD-RFE (Ethyl Acetate, 78%; Polyisocyanate, 22%). In some embodiments, and particularly in those wherein outer layer 52 comprises a polyurethane, intersections 178 between layered sheet L and tube T may include, in addition to adhesive 180, a deposit of polyurethane 202 to assist in bonding or adhering layered sheet L, and in particular outer layer 52 of layered sheet L to raised portion R. Such polyurethane 202 may be deposited with a nozzle or other means known to those of skill in the art (see, e.g., FIG. 42). After the polyurethane hardens, in some embodiments the polyurethane may be buffed by a suitable brush or the like to smoothly blend the surface of the grip while in other embodiments, the polyurethane is not buffed. The proximity of layered sheet L to raised portion R may not be uniform. For example, in some embodiments, portions of raised portion R may be within approximately ⅛ inch, 1/16 inch or in direct contact with the layered sheet L around substantially the entire circumference of the raised portion R.

In certain embodiments, thickness t_(R) of raised portion R is generally constant along its entirety and is configured to be approximately equal to thickness t_(L) of the layered sheet L (see, e.g., FIG. 40). In some embodiments, the approximately equal thicknesses of portion R and layered sheet L promote a substantially smooth surface interface 176 between the two as they cooperate to define gripping surface GS of grip G.

As mentioned above, it should be understood that the outer surface of a grip embodying the disclosure herein may be coated by means of a brush or spray or the like with a thin layer of polymer such as polyurethane (not shown) to, for example, protect such surface, add tackiness thereto and/or increase the durability thereof.

In some embodiments, tube T includes rubber with an IRHD hardness rating (International Rubber Hardness Degrees) between approximately 60 and 80 degrees. In some embodiments, raised portion R also has an IRHD hardness rating between approximately 60 and 80 degrees. As discussed above, in some embodiments outer layer 52 includes polyurethane. In some embodiments, outer layer 52 has an IRHD hardness rating of between approximately 40 and 60 degrees. In some embodiments, the ratio of the hardness of outer layer 52 and raised portion R is approximately 1 to 1. In some embodiments, the hardness ratio is between approximately 1 to 2 and approximately 1 to 1. In some embodiments where the hardness ratio is approximately 1 to 1, one or more other characteristics, such as tackiness, durability, color, or friction enhancing pattern on the outer surface, may differentiate raised portion R and outer layer 52 on the gripping surface.

In one application, layered sheet L is adapted to provide a tacky, shock absorbing surface while raised portions R are configured to provide more durable surfaces. A user grasps the grip G with her left hand closest to cover 10. At least a portion of finger zone FZ of raised portion R₂ engages at least a portion of the pads of a user's fingers closest to the user's left palm. The upper portion of R₂ may extend a width w₂ sufficient to provide a palm zone PZ on the front of grip G adapted to engage the meaty portion of the palm of the user's left hand. In some embodiments, that width w₂ extends 100% of the circumference of tube T. The user's left and right thumbs may then rest on the front of grip G where raised portion R₁ is configured to engage the thumbs.

FIGS. 43 through 47 illustrate a modified tube T and layered sheet L. As discussed above, in general connecting surface 46 desirably extends between support surface 12 and exposed surface E of raised portion R and forms an angle α with a line tangent to the intersection of connecting surface 46 of raised portion R and support surface 12 of tube T. Layered sheet L is generally configured to engage connecting surface 46. As shown in, for example FIG. 44, connecting surface 46 a extends between support surface 12 and exposed surface E₁ of raised portion R₁ to form an angle α₁. In some embodiments, connecting surface 46 is transverse to support surface 12 such that angle α is approximately 90 degrees and edges 190 and 192 of layered sheet L are not skived so that they form a complementary angle. In some embodiments, it may be advantageous to configure tube T such that angle α is greater than 90 degrees. In some embodiments, angle α is in the range of approximately 90 and 175 degrees. In some embodiments, angle α is in the range of approximately 95 and 150 degrees. In some embodiments, for example the embodiment shown in FIGS. 43 through 47, angle α is approximately 120 degrees. FIG. 45 illustrates layered sheet L after being skived along its edges to complement the angle α of tube T illustrated in FIGS. 43 and 44. FIGS. 46 and 47 show layered sheet L being wrapped about tube T and bonded to tube T as described above.

Alternatively, it may be advantageous to configure tube T such that angle a is less than 90 degrees (not shown). In some embodiments, angle α is in the range of approximately 5 and 90 degrees. In some embodiments, angle α is in the range of approximately 25 and 85 degrees. Forming connecting surface 46 of raised portion R to have an angle α less than 90 degrees allows the edges of layered sheet L to be hidden beneath at least a portion of connecting surface 46, particularly if thickness t_(R) of raised portion R is greater than thickness ti, of layered sheet L. In some embodiments, connecting surface 46 describes an angle α other than 90 degrees, and yet some or all of the edges of layered sheet L are not skived to complement the angle α described by connecting surface 46. In some such embodiments, particularly in those wherein angle α is less than 90 degrees, gaps between layered sheet L and raised portion R may be left empty or filled with an adhesive or other bonding agent.

In some embodiments, connecting surface 46 describes a varied angle α. The edges of layered sheet L may have skiving to complement some or all of those angles.

In addition to being attached to tube T configured for use with irons, as shown in FIG. 2, any of the layered sheets disclosed herein may also be attached to a tube configured for use with putters (not shown). Such a putter tube may include a substantially flat region as shown, for example, in Applicant's U.S. Pat. Nos. 6,843,732 and 6,857,971. In addition, in such a putter grip, alternative arrangements of raised portions R may be employed to accommodate various types of putting styles. For example, an additional finger zone FZ may be created on the front of the grip and a thumb zone TZ may be created on the back of the grip accommodate a player's “claw style” putting grip.

It will be understood that the foregoing is only illustrative of the principles of the inventions, and that various modifications, alterations and combinations can be made by those skilled in the art without departing from the scope and spirit of the inventions.

Referring to the drawings, FIGS. 48, 49 and 50 show a golf club C′ having a shaft 20′ upon the handle H′ of which is installed a prior art resilient grip GPA′. Grip GPA′ includes a polyurethane-felt strip S′ which is spirally wrapped about a resilient underlisting UPA′ similar to that shown and described in my U.S. Pat. No. 6,386,989. A plurality of such prior art golf club grips are inserted into and removed form a conventional golf bag B′ during play. As noted in FIG. 50, during such insertion and removal, the grips GPA′ of the golf clubs have sliding contact with other golf club grips and the sides of the golf bag B′. Such contact causes the upper end of the resilient strips to unravel from the golf club handles. In FIGS. 48 and 49 there is shown the manner in which unraveling of the upper end 19′ of resilient strip S′ takes place. Such unraveling not only detracts from the appearance of the grip, but is also distracting to a golfer when he takes a swing of the club because of the rough feel of the unraveled portion of the strip.

Referring now to FIGS. 51-59, there are shown the components of a preferred form of golf club grip G′ embodying the present invention. Such grip includes resilient underlisting sleeve U′, similar to that described in my U.S. Pat. No. 6,386,989. Sleeve U′ includes an integral cap 22′ at its upper end, while the lower end of the sleeve is formed with an integral nipple 24′. The upper portion of nipple 24′ is formed with a circumferential groove 25′ for a purpose described hereinafter. It should be particularly noted that the underside of cap 22′ is formed with a circumferentially extending slot 26′ which receives the upper end of the resilient sleeve 5′ of FIGS. 55-58 in a manner to be described hereinafter.

More particularly, strip S′ is fabricated from first and second individual segments S1′ and S2′ of different widths, with segment S1′ preferably being wider than segment S2′. Segment S1′ includes a bottom backing layer, 30′ (preferably of felt) having an inner or bottom surface which is adhered to the aforedescribed underlisting sleeve U′. Segment S1′ also includes a top layer of a suitable resilient plastic material, such as a smooth closed-pore polyurethane layer, generally designated 34′, with the polyurethane layer being bonded to the upper surface of its adjacent bottom layer. The segment S1′ may be formed with vertical air-passing perforations (not shown) such as described in my U.S. Pat. No. 5,645,501 issued Jul. 8, 1997. Segment S2′ is similar in construction to segment SF and includes an open-pored bottom backing layer, generally designated 36′ (preferably of felt), having an inner or bottom surface which is adhered to underlisting sleeve U′. Segment S2′ also includes a top layer 40′ of a suitable resilient plastic material such as polyurethane layer, with the polyurethane layer being bonded to the upper surface of its adjacent backing layer 36′. The polyurethane layer of each strip segment S1′ and S2′ may be formed in a conventional manner by coating a felt strip with one or more solutions of polyurethane (e.g., polyester or polyether) dissolved in a dimethyl formamide (DMF), immersing the coated strip in water baths to displace the DMF and cause the urethane to coagulate, and finally driving off the water by the application of pressure and heat. In this manner, pores are formed in the polyurethane layer, while the underside of the polyurethane layer is bonded to the upper surface of the felt layer. The thickness of the polyurethane layer is preferably about 0.2-1.40 millimeters and the thickness of the felt layer is about 0.7-1.90 millimeters.

The felt layers 30′ and 36′ serve as backing layers for the polyurethane layer 34′ and polyurethane coating 40′ so as to provide strength for the polyurethane. The felt also cooperates with the polyurethane to assist in cushioning the shocks applied to a grip when a golf ball is struck by a golf club. It should be noted that other materials may be substituted for the felt as a backing layer to provide strength for the polyurethane and to cushion shocks, e.g., a synthetic plastic such as an ethylene-vinyl acetate copolymer, commonly known as EVA. The felt may be fabricated of conventional suitable materials such as nylon, cotton, polyester or the like.

The entire underside of backing layer 30′ of segment S1′ is provided with an adhesive 54′ initially covered in a conventional manner by a peel-away tape 56′. Peel-away tape 56′ includes a thin band 56B′ (not shown) which can be pulled off the main body of tape 56′ to expose adhesive 54′ disposed on one edge of segment S1′, while the tapes' main body remains on the adhesive covering the remainder of the segment S1′.

Referring now to FIG. 58, the side edges of the polyurethane layer 34′ of segment S1′ are formed with sidewardly and outwardly extending reinforcement side edges 46′ and 47′. The side edges of the polyurethane layer 40′ of segment S2′ are also formed with sidewardly and outwardly extending reinforcement side edges 48′ and 49′. In FIG. 58, the side edges of the felt layer 34′ of segment S1′ have been skived to form outwardly and upwardly slanted side edges 50′ and 51′. Similarly, the side edges of felt layer of segment S2′ have been skived to form outwardly and upwardly slanted side edges 52′ and 53′. The underside of segment S2′ is covered with an adhesive 58′ initially covered by a peel-away tape 59′ (FIG. 56). To combine segments S1′ and S2′ into composite strip S′, reinforced side edge 49′ of segment S2′ is then placed underneath skived side edge 50′ of segment S1′ as shown in FIG. 58 and pressed onto segment S1′. The strip S′ is then cut on both ends to provide the leading edge and trailing edges 60′ and 62′.

It should be particularly noted that the upper area of polyurethane layer 40′ of segment S2′ inwardly of the recessed side edges may be embossed with depressed indicia I′, such as the name of the manufacturer of the golf club grip. Such embossing serves not only as a decorative enhancement of the golf club grip, but additionally, the embossing process densifies the polyurethane layer 40′ so as to reduce stretching of the second segment and thereby increase the hoop strength of the strip S′. It is also desirable to mold the polyurethane layer 34′ of segment S1′ in a first color while polyurethane layer 40′ of segment S2′ is molded in a second color that contrasts with the first color. With this arrangement, a multicolored grip having a pleasing appearance will result when the strip S′ is spirally wrapped about an underlisting sleeve.

Referring now to FIGS. 59-62, to secure the upper or leading edge 60′ of resilient strip S′ within the circumferential slot 26′ of cap 22′, the upper edge of the strip is manually urged into the confines of the slot 26′ (FIG. 60). After the upper edge of the strip S′ has been firmly positioned within the slot 26′, the strip is spirally wrapped downwardly along the outer surface of the underlisting sleeve U′ (FIG. 61). When the strip S′ has been spirally wound to a position wherein its lower or trailing edge 62′ is disposed in horizontal alignment with the lower portion of nipple groove 25′ the lower end portion of the strip is manually urged into the confines of the groove by temporarily expanding the peripheral lip 70′ formed outwardly of the groove so as to admit the lower edge of the strip into the groove. When the lip 70′ returns to its original position, the lip will securely retain the lower end of the strip to the upper portion of the nipple as shown in FIGS. 63-65. The resulting grip G′ embodying the present invention is shown in FIG. 66. Referring thereto, it will be seen that the upper end of strip S′ is restrained against unraveling by being locked in cap slot 26′ while the lower end of such strip is restrained against unraveling by nipple lip 70′. The aforedescribed arrangement for securing the upper edge of the strip S′ is particularly useful in securely retaining a two-piece strip on the upper portion of the underlisting sleeve since the narrower strip segment has a tendency to become unraveled.

The spiral wrapping of the strip S′ about the underlisting U′, and the positioning of the upper and lower edges of the strip within the slot 26′ and groove 25′ may take place when the underlisting sleeve is positioned upon a mandrel M′ in a conventional manner. After the strip has been secured upon the underlisting U′, the sleeve and strip combination may be removed from the mandrel and slipped onto the handle portion of a golf club shaft.

It should be understood that various modifications and changes may be made with respect to the above-described embodiment without departing from the scope of the present invention. By way of example, the resilient strip may be of one-piece construction such as that shown in my aforementioned U.S. Pat. No. 6,386,989, rather than the two segment construction described hereinabove.

Referring to the drawings, in FIG. 67, a single panel grip G″ of one embodiment of the present invention is shown attached to the shaft 55″ of a golf club GC″. In FIG. 68, a single panel putter grip PG″ is shown attached to the shaft 57″ of a putter P″. Referring now to the remaining drawings, a preferred form of grip G″ includes a single panel S″ formed of a bonded-together outside or polymeric, preferably polyurethane, layer 60″ and an inside or polymeric, preferably ethylene-vinyl acetate copolymer (EVA), layer 62″, which is wrapped about and adhered to a resilient underlisting sleeve U of conventional construction.

The outside layer 60″ of the single panel in this disclosure is generally referred to as a polyurethane layer. Though polyurethane is the preferred material, other materials could be used and achieve some advantages. In particular, other polymeric compounds can be used to create the outer layer and achieve some advantages. Similarly, the inside layer 62″ is generally referred to as an EVA layer. Though EVA is preferred, it is understood that other polymeric layers can be used in alternative embodiments of this invention. In another embodiment, the inside layer may comprise a fabric, more preferably felt.

Referring to FIGS. 69-72, the EVA layer 62″ has its exterior surface secured to the interior surface of polyurethane layer 60″ with an adhesive 30″, with such polyurethane layer 60″ preferably being coagulated to define pores (as shown in FIG. 72). One preferred method of forming a suitable polyurethane-EVA sheet (not-shown) is disclosed in U.S. Pat. No. 6,627,027 issued to Applicant on Sep. 30, 2003. One preferred method of forming the polyurethane layer 60″ of the aforementioned polyurethane-EVA sheet is disclosed in, for example, U.S. patent application Ser. No. 10/746,764, filed by Applicant on Dec. 23, 2003. Once the polyurethane-EVA sheet is formed, the sheet is preferably press cut in the conventional way to form the shaped panel S″ shown in FIG. 69. The same press cut desirably also forms notches N1″, N2″ in the panel S″ at the center of the top edge 107″ and bottom edge 108″, respectively. The notches N1′, N2′ serve as markings to help center the panel S″ on the underlisting sleeve U″. Though there are other methods of centering the panel S″, these notches N1″, N2″ are preferred because they reduce cost and do not affect the contours of the finished grip G″. One example of another method of centering the panel S is discussed below in relation to FIGS. 82-85.

Preferably, the thickness of the polyurethane layer will be about 0.3-0.5 millimeters and the thickness of the EVA layer about 0.8 -1.7 millimeters. The polyurethane layer 60″ provides a cushioned grasp of a golfer's hands on a golf club and also enhances the golfer's grip by providing increased tackiness between the player's hand and the grip. The EVA layer 62″ provides strength to the polyurethane layer and serves as a moisture resistant means for attaching the secured-together polyurethane and EVA panel to underlisting sleeve U″.

Referring now to FIGS. 73-81 there is shown a first mold M″ which may be utilized to form a friction enhancing pattern 63″ on the outer surface of polyurethane layer 60″, and top and bottom heat depressed horizontal edges 64″ and 65″ along the top and bottom edges 107″, 108″ of the single panel S″ and depressed horizontal edges 66 a″, 66 b″ along the sides of the panel 109″, 110″, respectively. Mold M″ includes a base plate B″ and a heated platen 67″ formed with a cavity 68″. The ends of the cavity 68″ are provided with depending protrusions 69″ that engage the outer surface of the polyurethane layer 60″ so as to form the depressed friction enhancing pattern 63″, as seen in FIG. 75. In FIG. 74, depending protrusions 69 a″, 69 b″ form recessed edges 66 a″, 66 b″, respectively. In FIG. 77, it will be seen that the right-hand edge of the cavity 68″ is formed with a shoulder 70″ which engages the top edge 107″ of the panel S″ to form heat recessed top edge 64″ in polyurethane layer 60″. The left-hand side of the cavity is formed with a similar shoulder 71″ to form the heat depressed recessed bottom edge 65″ along the bottom edge 108″ of the panel S″ (FIG. 76).

In alternative embodiments, other patterns may be formed on the outer surface of the polyurethane layer 60″. FIG. 78 shows one alternative design in which the mold M″ forms the friction enhancing pattern 63″ but does not form the heat depressed edges 64″, 65″, 66 a″, 66 b″ along the periphery edges 107″, 108″, 109″, 110″ of the panel S″. As seen in FIG. 79, another alternative design leaves the majority of the outside layer 60″ smooth while visual indicia, such as logo 116″, is placed near the bottom edge 108″ of the panel S″. In FIG. 80, yet another embodiment of the friction enhancing pattern is shown. The second pattern 118″ incorporates visual indicia extending the majority of the length of the panel surrounded by a tread pattern similar to the friction enhancing pattern 63″ shown in FIG. 78. FIG. 80 also shows an alternative means for imputing decorative designs or logos on the grip panel S″. Stamped visual indicia, such as logo 114″, is ink stamped onto the polyurethane layer 60″ using a suitable ink known to those of skill in the art. Preferably, the ink is waterproof and heat resistant and, more preferably, formulated to resist degradation when coming into contact with the lubrication fluid or solvent used to apply the completed grip G″ (underlisting U″ with panel S″) over the end of a golf club GC″ shaft 55″ (FIG. 67) or a putter P shaft 57″ (FIG. 68). It is to be understood that these are representative and many other patterns and stamps may be used with this polyurethane-EVA single panel grip.

FIG. 81 is a cross-sectional view taken along the line designated 81-81 of FIG. 78. It shows the friction enhancing pattern 63″ formed on the contiguous polyurethane layer 60″.

Referring now to FIGS. 82-85 there is shown a second mold M2″ which may be utilized in making a single panel grip G″ of one embodiment of the present invention. Panel S″ is shown inverted from its position in first mold M″. The mold M2″ includes a base plate 71″ and a heated platen 72″ formed with a cavity 73″. The base plate is also formed with a cavity 74″ that receives the polyurethane layer 60″ while the EVA layer 62″ is received within the cavity 73″ of the heated platen 72″. The top and bottom edges and the side edges of the heated platen 72″ are formed with a depending peripheral shoulders 76 a″, 76 b″ that engage the top and bottom edges 107″, 108″ and the side edges 109″, 110″ of the EVA layer 62″. When the heated platen 72″ is urged downwardly towards the EVA layer the periphery thereof will be depressed by the shoulders 76 a″, 76 b″ and heat will be transferred through the EVA layer to densify the peripheral edges of the polyurethane layer 60″. The densification is effected by the heat transferred from the shoulders 76 a″, 76 b″ through the EVA layer 62″. An alternative to the centering notches N1″, N2″ can be formed at the same time when heated platen 72″ of second mold M2″ is also provided with a depending spur 72 a″ (FIG. 83) which forms a score line SL-1″ along the longitudinal center of the EVA layer 62″ shown in FIG. 85. In alternative embodiments, the heated platen of second mold M2″ lacks depending shoulders 76 a″, 76 b″. Rather, it only has depending spur 72 a″ to form score line SL-1″ without densifying the peripheral edges 107″, 108″, 109″, 110″ of polyurethane layer 60″.

Referring now to FIGS. 86-89, the peripheral edges of the panel S″ are shown being skived by a pair of rotating knives 120″ and 122″, which engage the top edge 107″ and bottom edge 108″ of the panel S″, as shown in FIG. 86, and a single rotating knife 124″. Knives 120″ and 122″ form top and bottom skived edges 130″, 132″. Knife 124″ is shown forming skived side edge 134″ on one side of the panel S in FIG. 87 and the other skived side edge 136″ in FIG. 88 after the first side 109″ has been skived. A pressure plate 83″ is utilized to secure the panel S″ on base 84″ during the skiving operation. It will be noted that the skiving on the opposite sides 109″, 110″ of the panel S″ are preferably parallel to one another, as seen in FIG. 88. Preferably, the skiving will have a width of about 4.0 -6.0 millimeters. In alternative embodiments, the top edge 107″ and/or bottom edge 108″ is not skived.

Referring now to FIGS. 90-93, there is shown an underlisting sleeve U″ formed of a resilient material such as a natural or synthetic rubber or plastic. Sleeve U″ may include an integral cap 85″ at its top end, while the bottom end of the sleeve may be formed with an integral nipple 86″. The underside of the cap 85″ is preferably formed with a circumferentially downwardly extending slot 87″. The slot 87″ preferably receives the top skived edge 130″ of the panel S″ as described hereinafter. The nipple 86″ is preferably formed with an upwardly extending slot 88″ which is preferably defined by a peripheral lip 89″ formed outwardly of the slot 88″ so as to admit the bottom skived edge 132″ of the panel S″ in a manner to be described hereinafter. Preferably, underlisting sleeve U″ will be formed with centering notches N3″, N4″ indicating a middle point for application of the completed grip panel S″ to the underlisting sleeve U″ to form a complete grip G″. Alternatively, underlisting sleeve U″ may be formed with a vertically extending score line SL-2″ (not shown).

Referring now to FIGS. 94-103, the panel S″ is shown being applied to underlisting sleeve U″. In FIG. 94, the exterior surface of the underlisting sleeve U″ is shown receiving an adhesive 90″ by means of a nozzle, brush or the like. In FIG. 95, the interior surface of the EVA layer 62″ is shown receiving an adhesive 90″ by means of a nozzle, brush or the like.

FIG. 96 shows the panel S″ shown being wrapped around and adhered to the underlisting sleeve U″. During this operation, the notches N1″, N2″ of the panel S″ are disposed in alignment under notches N3″, N4″ of the underlisting sleeve U″. Alternatively, the score lines SL-1″ and SL-2″ may be disposed in alignment. In yet another embodiment, score lines may be used in combination with notches to center the panel S″ on the underlisting sleeve U″. Also, top skived edge 130″ of the panel S″ will be manually inserted within the slot 87″ of the underlisting cap 85″, while the bottom skived edge 132″ of the panel S″ is manually inserted within the slot 88″ formed within the nipple 86″ by temporarily flexing the peripheral lip 89″ outwardly (See FIGS. 109 and 110).

As indicated in FIGS. 101, 102 and 103, the skived side edges 134″, 136″ of the panel S″ will be adhered together by a suitable adhesive 90″ so as to define a seam 91″ extending through the panel. Because of the skived side edges 134″, 136″, the seam 91″ extends through the panel at an angle relative to the depth of the panel S″ so as to increase the length of such seam as compared to a seam extending parallel to the depth of the panel. Increased length of the seam affords a stronger bond. As one of skill in the art would appreciate and as discussed in my earlier disclosures, there are different ways of attaching the panel to the underlisting sleeve U″. A suitable adhesive 90″ used to join the EVA layers and to wrap the polyurethane/EVA panel to the underlisting is preferably a combination of methyl-ethyl-ketone (C₆H₅CH₃) and TS008 polyurethane. As those of skill in the art will appreciate, these compounds can be combined in various ratios. However, one suitable ratio of the combination is 8:1. As one of skill in the art would appreciate and as stated in the disclosure of my U.S. Pat. No. 6,627,027, one can purchase EVA having an adhesive coating 30″ covered by a protective paper from the Ho Ya Electric Bond Factory, Xin Xing Ind. Area. Xin Feng W. Rd., Shi Jie Town Dong Guan City, Guan Dong, Province, China. Still other possibilities are contemplated for securing the panel S″ to the underlisting U″, including, but not limited to, the use of a tape, rather than liquid, form of adhesive 90″.

In one embodiment, the seam 91″ is left alone and the completed grip G-1″ resembles the grip in FIG. 98.

FIGS. 109 and 110 show enlarged cross-sectional views along the lines designated 104-109 and 110-110, respectively, of FIG. 108. They demonstrate the final placement of the top skived edge 130″ and the bottom skived edge 132″ of the panel S″ after the panel S″ has been adhered to the underlisting U″. It will be seen that the top edge skived edge 130″ of the panel S″ is securely disposed within the cap 85″ slot 87″. Similarly, the bottom skived edge 132″ is securely disposed within the nipple 86″ slot 88″. It is, of course, also possible to insert unskived top edge 107″ and/or unskived bottom edge 108″ into the respective slot 87″ or 88″. The complete grip is then removed from the mandrel 92″ and is ready to be slipped onto and adhered to the shaft of a golf club GC″ or putter P″ in a conventional manner.

Referring to FIGS. 104-108, an embodiment is shown after the panel S″ has been adhered to the underlisting sleeve U″. FIG. 104 shows the underlisting sleeve U″ supported by mandrel 92″ upon a base 93″ while a longitudinally extending heated pressure tooth 94″ (FIG. 105) is urged against the polyurethane layer 60″ at the outer edge of seam 91″. The heated tooth 94″ forms a small depression 95″ in the polyurethane layer 60″ aligned with the outer edge of the seam 91″ so as to further strengthen the seam 91″. An embodiment of a completed grip G-2″ is shown in FIG. 108.

FIGS. 111-114 show a golf club grip G-3″ similar to grip G-2″ with the exception that the depression 95″ is filled with hot polyurethane 96″ by a nozzle, brush or the like (FIG. 111). After the polyurethane 96″ hardens, it can be buffed by a suitable brush or the like 97″ to smoothly blend into the surface of the grip as shown in FIG. 112. Alternatively, channel 95″ is not buffed after it is filled with hot polyurethane 96″.

Referring now to FIGS. 115-118, there is shown another embodiment of a grip G-4″. Grip G-4″ does not use the channel 95″. Rather, seam 91″ is coated by a small deposit of hot polyurethane 96″ by means of a nozzle, brush or the like, as shown in FIG. 116. After the polyurethane 96″ hardens, it may be buffed by a suitable brush or the like 97″ to smoothly blend into the surface of the grip, as indicated in FIG. 117. Alternatively, the polyurethane 96″ is not buffed.

In still another embodiment, the adhesive 90″ is sprayed on the EVA layer 62″ such that it covers only the EVA layer 62″ and does not extend to cover the edges of the polyurethane layer 60″. After the panel S″ is wrapped around the underlisting sleeve U″, hot polyurethane 96″ may be injected between the polyurethane layers of the seam 91″ by a needle, brush, sprayer or the like. After the polyurethane 96″ hardens, it may be buffed by a suitable brush or the like 97″ to smoothly blend in the surface of the grip any polyurethane 96″ spilling from the seam. Alternatively, the polyurethane is not buffed.

Referring to FIGS. 119-129, there is shown a modification of the grips of FIGS. 98-118. In FIGS. 119-121, hot polyurethane 96″ is shown being coated over the seam 91″ by a nozzle, brush or the like. In 122-124, hot polyurethane 96″ is shown filling the depression 95″ by a nozzle, brush or the like. In another embodiment, hot polyurethane 96″ is injected between the edges of the polyurethane layer along the seam. FIG. 125 shows a third mold M3″ having a heated platen 100″, the underside of which is formed with a segment 63 a″ of the friction enhancing pattern 63″, which is embossed on the surface of the polyurethane layer 60″ of the grip. The heated platen 100″ is depressed against the outside surface of the polyurethane layer 60″ over the area of the seam 91″ while the polyurethane deposit 96″ is still hot. With this arrangement, the area of the exterior of the polyurethane layer 60″ outwardly of the seam 91″ is formed with the friction enhancing segment 63 a″ of FIG. 126 whereby the segment 63 a″ merges with the friction enhancing pattern 63″ previously molded on the polyurethane layer 60″ of the grip G″. FIG. 129 shows such a grip G-5″ with the merged friction enhancing pattern 63″ placed over and adhered to the shaft 55″ of a golf club GC″. Alternatively, in another embodiment, the heated platen 100″ may be urged against the naked seam 91″ to form the friction enhancing pattern without first coating in or along the seam 91″ with hot polyurethane 96″. Pressing the friction enhancing pattern 63″ directly to the seam 91″ eliminates a step in the production process and therefore reduces the costs of production.

Referring now to FIGS. 130-139, there is shown a polyurethane-EVA single panel grip PG″ for use with a conventional putter P″. The grip PG″ includes a resilient underlisting UP″ (FIGS. 130-134), which is generally similar to the aforedescribed underlisting U″, except that underlisting sleeve UP″ is not of an annular configuration. Instead, the front surface 98″ of underlisting sleeve UP″ is of flat configuration in accordance with the design of most putters in general use. It should be understood that underlisting sleeve UP″ receives a single panel SP″ of polyurethane-EVA configuration, similar to the aforedescribed single panel S″. Such single panel SP″ is wrapped about and adhered to the underlisting sleeve in the same manner as described hereinbefore with respect to the panel P″ in the polyurethane-EVA single panel grips G-1″-G-5″, with like parts of the two grips marked with like reference numerals. Similarly, if a tooth 94′″ is used to create a channel 95′″, that channel 95′″ may be left alone or filled with hot polyurethane 96′″ and left alone or buffed with a brush or the like 97′″ (refer to FIGS. 104-129 for examples of possible modifications to the grips herein disclosed). In one embodiment, the panel SP′ is smooth as shown in FIG. 135. Because a putter P′ is generally subjected to less forces due to the shortened putting swing as compared to the generally longer swing associated with other clubs, it is contemplated that putter grip PG″ does not require the friction enhancing pattern 63′″. Alternatively, the panel SP″ may incorporate a smaller heat embossed visual indicia such as logo 114′″ (not shown), a heat embossed friction enhancing pattern 63′″ (not shown), an inked visual indicia 118′″ (not shown), a larger heat embossed pattern extending the majority of the length of the panel 118′″ (not shown) or any combination or modification thereof.

Referring now to 140-143, there is shown embodiments of the grip having a polyurethane-felt single panel.

It should be understood that the outer surface of a grip embodying the present invention may be coated by means of a brush, nozzle, sprayer or the like with a thin layer of polymeric material, preferably polyurethane (not shown), to protect such surface, add tackiness thereto and increase the durability thereof.

Golf club grips of the present invention provide several advantages over existing wrapped grips and single panel grips. Additionally, such grips have the appearance of molded, one-piece grips familiar to professional and low-handicap golfers. Although some of such golfers are reluctant to use a non-traditional wrapped club, they are willing to play with a structurally integral grip of the present invention since such grip affords the shock-absorbing and tackiness qualities of a wrapped grip. Further, the use of a polymeric material such as EVA as the inner layer in some of the embodiments lightens the grip of the club and prevents undue absorption of moisture into the grip of the club.

Various modifications and changes may be made with respect to the foregoing detailed description without departing from the spirit of the present invention. 

1.-25. (canceled)
 26. A grip for the handle of an article, said grip comprising: an underlisting sleeve configured to be telescopically slipped onto the handle of the article, said underlisting sleeve comprising an upper end including an integral cap and a lower end including an integral nipple and an attachment surface between said upper and lower ends, said lower end including an opening configured to receive said handle of the article; a single panel comprising an inner strength layer and an outer cushioning layer, the single panel comprising an upper edge, a lower edge, a first side edge, and a second side edge; and said single panel wrapped about and adhered to the attachment surface of said underlisting sleeve such that the first side edge and the second side edge form a longitudinal seam and wherein at least a portion of the cap extends longitudinally above the single panel and at least a portion of the nipple extends longitudinally below the single panel.
 27. The grip as in claim 26, wherein a cross section of the grip near the cap is cylindrical and a cross section of the grip near the nipple is cylindrical and smaller than the cross section of the grip near the cap.
 28. The grip as in claim 26, wherein the cap comprises a hole.
 29. The grip as in claim 28, wherein the hole in the cap has a smaller diameter than the opening in the lower end of the underlisting sleeve
 30. The grip as in claim 26, wherein an outermost surface of the outer cushioning layer forms a substantially smooth interface between the cap and the nipple.
 31. The grip as in claim 26, wherein outer cushioning layer comprises a friction enhancing pattern.
 32. The grip as in claim 31, wherein the friction enhancing pattern is heat compressed into the outer cushioning layer.
 33. The grip as in claim 26, wherein the single panel includes a centering feature and the underlisting sleeve includes a centering feature and wherein the panel is adhered to the underlisting sleeve such that the centering feature of the single panel is aligned with the centering feature of the underlisting sleeve.
 34. The grip as in claim 26, wherein the grip includes a flat region opposite the longitudinal seam.
 35. The grip as in claim 34, wherein an upper region of the grip near the upper end of the underlisting sleeve flares away from the flat region.
 36. The grip as in claim 26, wherein the single panel abuts a lower portion of the cap.
 37. The grip as in claim 26, wherein the lower portion of the cap comprises a downwardly extending slot and the panel extends into the downwardly extending slot.
 38. The grip as in claim 26, wherein the single panel abuts an upper portion of the nipple.
 39. The grip as in claim 37, wherein the upper portion of the nipple comprises an upwardly extending slot and the single panel extends into the upwardly extending slot.
 40. The grip as in claim 26, further comprising a coating over substantially the entire outer cushioning layer. 